Absorbent articles comprising stretch laminates

ABSTRACT

An absorbent article includes a chassis comprising a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet, and at least one elastically elongatable panel joined to the chassis. The elastically elongatable panel includes an ultrasonically bonded stretch laminate. The stretch laminate includes a first nonwoven and a second nonwoven, and an elastomeric film sandwiched between the first and second nonwovens. The elastomeric film has two surfaces and a skin on at least one of the surfaces. The stretch laminate further incudes a first zone and second zone. In the second zone, the laminate is elastically extensible in a stretch direction. In the first zone, the laminate is unactivated and the elastomeric film comprises activation stripes.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of application Ser. No. 16/658,225,filed Oct. 21, 2019, which is a continuation of application Ser. No.15/360,289, filed Nov. 23, 2016, which is a continuation of applicationSer. No. 14/265,629, filed Apr. 30, 2014, now U.S. Pat. No. 9,533,067issued on Jan. 3, 2017, which claims the benefit of U.S. ProvisionalApplication No. 61/819,151, filed May 3, 2013 and U.S. ProvisionalApplication No. 61/896,816, filed Oct. 29, 2013, the substances of whichare incorporated herein by reference.

FIELD OF THE INVENTION

The present disclosure generally relates to stretch laminates andabsorbent articles, such as diapers, pants, or the like, made using suchstretch laminates.

BACKGROUND OF THE INVENTION

Disposable absorbent articles, such as diapers, are designed to containbodily wastes and prevent soiling of the wearer's clothing and/or otheritems (e.g., a bed, a chair, a blanket, etc.). The fit of the article tothe wearer's body is important in ensuring that these wastes arecontained. Such articles are also designed to be cost-effective, andtherefore manufacturers generally make the articles applicable for useby individuals with a wide range of body types. Accordingly, new andimproved disposable absorbent articles that both conform to a wide rangeof body types and fit snuggly to the user to contain wastes and limitleakage are of continued interest.

One way in which manufacturers attempt to balance the competinginterests of proper fit and variation in body type is through the use ofexpandable materials. One such group of materials is known as stretchlaminates. As the name suggests, these materials are actually compositesof individual components that are laminated together, through the use ofan adhesive, for example. A typical stretch laminate will attempt tocombine one or more layers of cover material with one or more layers orstrands of an elastomeric material.

Complications arise in that stretch laminates are notoriously difficultand expensive to manufacture. Considerable effort has gone intoproposing new types of stretch laminates and new methods for thefabrication of stretch laminates. In particular, a considerable numberof patents discuss the difficulties of fabricating these laminates, andthe significant and extensive steps that must be undertaken to preparethese laminates. Thus, there is a continuing need to provide new stretchlaminates, new methods of fabricating better performing and/or cheaperstretch laminates, and new absorbent articles that comprise such stretchlaminates.

SUMMARY OF THE INVENTION

In one aspect, an absorbent article includes i) a chassis comprising atopsheet, a backsheet, and an absorbent core disposed between thetopsheet and the backsheet and ii) at least one elastically elongatablepanel joined to the chassis. The elastically elongatable panel includesan ultrasonically bonded stretch laminate. The stretch laminate includesa first nonwoven and a second nonwoven, and an elastomeric filmsandwiched between the first and second nonwovens. The elastomeric filmhas two surfaces and a skin on at least one of the surfaces. The stretchlaminate further incudes a first zone and second zone. In the secondzone, the laminate is elastically extensible in a stretch direction. Inthe first zone, the laminate is unactivated and the elastomeric filmcomprises activation stripes.

In another aspect, an absorbent article includes i) a chassis comprisinga topsheet, a backsheet, and an absorbent core disposed between thetopsheet and the backsheet and ii) at least one elastically elongatablepanel joined to the chassis. The elastically elongatable panel includesan ultrasonically bonded stretch laminate comprising a first nonwovenand a second nonwoven, and an elastomeric film sandwiched between thefirst and second nonwovens. The elastomeric film has two surfaces and askin on at least one of the surfaces. The stretch laminate includes afirst zone and second zone. In the second zone, the laminate iselastically extensible in the stretch direction. In the first zone, thelaminate is unactivated. At least a portion of the skin of theelastomeric film is located in the first zone and wherein said portionof the skin has a plurality of wrinkles and the wrinkles have furrows.

In a further aspect, an absorbent article includes i) a chassiscomprising a topsheet, a backsheet, and an absorbent core disposedbetween the topsheet and the backsheet and ii) at least one elasticallyelongatable panel joined to the chassis. The elastically elongatablepanel comprises an ultrasonically bonded stretch laminate. The stretchlaminate comprises a first nonwoven and a second nonwoven, and anelastomeric film sandwiched between the first and second nonwovens. Theelastomeric film has two surfaces and a skin on at least one of thesurfaces. The stretch laminate comprises a first zone and second zone.In the second zone, the laminate is elastically extensible in thestretch direction; and in the first zone, the laminate is inelastic andthe elastomeric film comprises activation stripes. The first and secondnonwovens are directly bonded.

Additional aspects of the disclosure are defined by the claims of thispatent.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter that is regarded as thepresent invention, it is believed that the invention will be more fullyunderstood from the following description taken in conjunction with theaccompanying drawings. Some of the figures may have been simplified bythe omission of selected elements for the purpose of more clearlyshowing other elements. Such omissions of elements in some figures arenot necessarily indicative of the presence or absence of particularelements in any of the exemplary embodiments, except as may beexplicitly delineated in the corresponding written description. None ofthe drawings are necessarily to scale.

FIG. 1A is a cross-sectional view of a first embodiment of a stretchlaminate according to the present disclosure;

FIG. 1B is a cross-sectional view of a second embodiment a stretchlaminate according to the present disclosure;

FIG. 2 is a SEM photomicrograph showing a cross-sectional view of aportion of an elastomeric film that has not been pre-activated;

FIG. 3 is a magnified version of the SEM photomicrograph of FIG. 2;

FIG. 4 is a SEM photomicrograph showing a cross-sectional view of aportion of a pre-activated elastomeric film;

FIG. 5 is a magnified version of the SEM photomicrograph of FIG. 4;

FIG. 6 is a transmitted light photomicrograph of a top view of a portionof an elastomeric film that has not been pre-activated;

FIG. 7 is a transmitted light photomicrograph of a top view of a portionof a pre-activated elastomeric film;

FIG. 8 is a SEM photomicrograph showing a cross-sectional view of aportion of a stretch laminate that includes an elastomeric film that hasnot been pre-activated.

FIG. 9 is a magnified version of the SEM photomicrograph of FIG. 8;

FIG. 10 is a SEM photomicrograph showing a cross-sectional view of aportion of a stretch laminate that includes an elastomeric film that hasbeen pre-activated;

FIG. 11 is a magnified version of the SEM photomicrograph of FIG. 10;

FIG. 12 is a top view of an exemplary absorbent article includingsections made of a stretch laminate according to the present disclosure,with a section of a topsheet removed to expose an underlying absorbentcore;

FIG. 13 is a perspective view of the absorbent article of FIG. 12 shownin its contracted state, i.e., with the contraction induced by elasticmembers;

FIG. 14 is a top view of an exemplary ear panel fabricated from astretch laminate according to the present disclosure; and

FIG. 15 is a schematic illustration of a continuous process for making astretch laminate according to the present disclosure.

FIG. 16 is a schematic illustration of a top view of a T-Peel testsample.

FIG. 17 is a schematic illustration of a cross-sectional view of theT-Peel sample of FIG. 16, taken along line 17-17.

FIG. 18 is an exemplary chart plotting T-Peel curves generated using theT-Peel test method.

The exemplary chart plots T-Peel data for Example 2.

DETAILED DESCRIPTION OF THE INVENTION Definitions

As used herein, the following terms have the following meanings:

The term “absorbent article” refers to a device that absorbs andcontains liquid, and more specifically, refers to a device that isplaced against or in proximity to the body of the wearer to absorb andcontain the various wastes/exudates discharged from the body.

The terms “activated” and “pre-activated” refer to a process ofmechanically deforming a material in order to increase the extensibilityof at least a portion of the material. A material may be activated orpre-activated by, for example, incrementally stretching the material inat least one direction.

The terms “adhesively bonded” or “adhesively laminated” refer to alaminate wherein an adhesive is used to bond an elastomeric material toat least one cover layer.

The term “attached” refers to elements being connected or united byfastening, adhering, bonding, or by any other method suitable forconnecting the elements together and to their constituent materials.Many suitable methods for attaching elements together are well-known,including adhesive bonding, pressure bonding, thermal bonding,ultrasonic bonding, mechanical fastening, etc. Such attachment methodsmay be used to attach elements together over a particular area eithercontinuously or intermittently.

The term “diaper” refers to an absorbent article generally worn byinfants and incontinent persons about the lower torso and having thegeneral form of a sheet, different portions of which are fastenedtogether to encircle the waist and the legs of the wearer.

The term “disposable” refers to absorbent articles that generally arenot intended to be laundered or otherwise restored or reused asabsorbent articles, i.e., they are intended to be discarded after asingle use and, preferably, to be recycled, composted or otherwisedisposed of in an environmentally compatible manner.

The term “disposed” is used to mean that an element(s) is formed (joinedand positioned) in a particular place or position as a unitary structurewith other elements or as a separate element joined to another element.

The term “extensible” refers to the property of a material, wherein:when a biasing force is applied to the material, the material can beextended to an elongated length of at least 110% of its original relaxedlength (i.e., can extend 10%), without a rupture or breakage thatrenders the material unusable for its intended purpose. A material thatdoes not meet this definition is considered inextensible. In someembodiments, an extensible material may be able to be extended to anelongated length of 125% or more of its original relaxed length withoutrupture or breakage that renders the material unusable for its intendedpurpose. An extensible material may or may not exhibit recovery afterapplication of a biasing force.

Throughout the present disclosure, an extensible material is consideredto be “elastically extensible” if, when a biasing force is applied tothe material, the material can be extended to an elongated length of atleast 110% of its original relaxed length (i.e., can extend 10%),without rupture or breakage which renders the material unusable for itsintended purpose, and when the force is removed from the material, thematerial recovers at least 40% of its elongation. In various examples,when the force is removed from an elastically extensible material, thematerial may recover at least 60%, or at least 80%, of its elongation.

The terms “interior” and “exterior” refer respectively to the locationof an element that is intended to be placed against or toward the bodyof a wearer when an absorbent article is worn and the location of anelement that is intended to be placed against or toward any clothingthat is worn over the absorbent article. Synonyms for “interior” and“exterior” include, respectively, “inner” and “outer”, as well as“inside” and “outside”. Also, when the absorbent article is orientedsuch that its interior faces upward, e.g., when it is laid out inpreparation for setting the wearer on top of it, synonyms include“upper” and “lower” and “top” and “bottom”, respectively.

The term “joined” refers to configurations whereby an element isdirectly secured to another element by attaching the element directly tothe other element, and configurations whereby an element is indirectlysecured to another element by attaching the element to intermediatemember(s) which in turn are attached to the other element.

The term “lateral” or “transverse” refers to a direction running at a 90degree angle to the longitudinal direction and includes directionswithin ±45° of the lateral direction.

The term “longitudinal” refers to a direction running parallel to themaximum linear dimension of the article and includes directions within±45° of the longitudinal direction.

The term “pant” or “pants” refers to an absorbent article generally wornby infants and incontinent persons about the lower torso and having thegeneral form of a pair of short pants that can be applied or removedfrom the wearer without unfastening. A pant may be placed in position onthe wearer by inserting the wearer's legs into the leg openings andsliding the pant into position about the wearer's lower torso. While theterm “pant” is used herein, pants are also commonly referred to as“closed diapers”, “prefastened diapers”, “pull-on diapers”, “trainingpants” and “diaper-pants”.

The term “recovery” refers to ability of a material to return to itsoriginal size after it has been stretched.

The term “refastenable” refers to the property of two elements beingcapable of releasable attachment, separation, and subsequent releasablereattachment without substantial permanent deformation or rupture.

The terms “releasably attached,” “releasably engaged,” and variationsthereof refer to two elements being connected or connectable such thatthe elements tend to remain connected absent a separation force appliedto one or both of the elements, and the elements being capable ofseparation without substantial permanent deformation or rupture. Therequired separation force is typically beyond that encountered whilewearing the absorbent garment.

The “strain” or “percent strain” of a material is calculated bysubtracting the original length from the stretched length, then dividingthe result by the original length and multiplying by 100. The percentstrain is described by the equation below:

Percent Strain=% Strain=Strain=100*[(Ls−L ₀)/L ₀]

where L₀ is the original length of the stretch laminate (or elastomericfilm) at the beginning of the stretch step, and Ls is the length of thestretched laminate (or elastomeric film) at the end of the stretch step.A sample stretched from an original length of 10 mm to a length of 30 mmresults in a strain of 200%. Strain can be calculated in a lengthdirection, a width direction, or any direction there between.

The “set” or “percent set” of a material is calculated by subtracting anoriginal length from a final length, then dividing the result by theoriginal length and multiplying by 100. The percent set is described bythe equation below:

Percent Set=% Set=Set=100*[(L _(f) −L ₀)/L ₀]

where L₀ is an original length of the stretch laminate (or elastomericfilm) at the beginning of the stretch step, and L_(f) is a length of therelaxed stretch laminate (or elastomeric film) after it is relaxed fromthe stretch step. A sample is stretched from an original length of 10 mmto a length of 30 mm. Upon relaxing (removal of stress), the samplereturns to 15 mm. This results in a set of 50%. Set can be calculated ina length direction, a width direction, or any direction there between.

The term “wrinkle” refers to a small fold, ridge or crease.

Stretch Laminate

FIG. 1A illustrates an embodiment of a stretch laminate 20 according tothe present disclosure. According to this embodiment, laminate 20 mayinclude three layers: an elastomeric film 22, a first cover layer 24,and a second cover layer 26. However, according to other embodiments (asdepicted in FIG. 1B), a laminate 20′ may only include two layers: anelastomeric film 22′ and a cover layer 24′. Although the followingdescription will refer to the specific reference numbers in FIG. 1A, theprime versions of those numbers relating to the two layer embodiment ofFIG. 1B are also intended to be considered by the reader. For example,when the description refers to “elastomeric film 22 and first coverlayer 24 of stretch laminate 20”, it is intended that the reader alsoconsider the same description for “elastomeric film 22′ and cover layer24′ of stretch laminate 20′.”

Elastomeric film 22 and cover layers 24, 26 may be attached to eachother. For example, an adhesive 30, 32 may be disposed between layers22, 24, 26. As will be recognized, adhesive 30 may be initially disposedeither on a first surface 40 of elastomeric film 22 or a surface 42 ofcover layer 24, and adhesive 32 may similarly be initially disposedeither on a second surface 44 of elastomeric film 22 or a surface 46 ofcover layer 26. As assembled, adhesive 30 attaches surface 40 (and thuselastomeric film 22) to surface 42 (and thus cover layer 24), andadhesive 32 attaches surface 44 (and thus elastomeric film 22) tosurface 46 (and thus cover layer 26).

While the layers 22, 24, 26 appear to overlie each other completely,this need not be the case in all embodiments. For example, cover layers24, 26 may extend beyond elastomeric film 22, and may be attached one tothe other where the layers 24, 26 extend beyond elastomeric film 22;alternatively, cover layers 24, 26 may not extend to the limits ofelastomeric film 22. Also, while adhesive 30, 32 appears as a continuouslayer in FIGS. 1A and 1B, the adhesive may be applied as a continuouslayer or in a discontinuous pattern (such as a pattern of lines,spirals, or spots). Accordingly, the bonding can be the full width ofstretch laminate 20 or a partial width of the laminate (e.g.,intermittent or zone bonding). Further, alternative attachmentmechanisms may include heat bonding, pressure bonding, ultrasonicbonding, dynamic mechanical bonding, or any other suitable attachmentmechanism or combination of these attachment mechanisms.

Elastomeric film 22 of stretch laminate 20 includes a single layer ormultiple layer material that is elastically extensible. The elasticallyextensible material may be between about 10 μm and about 100 μm, orbetween about 20 μm and about 60 μm, or between about 30 μm and about 50μm, or in some embodiments, about 40 μm, in thickness. The elasticallyextensible material may comprise an elastomeric polyolefin, and in someembodiments, a polyolefin (POE) blown film. Non-limiting examples ofuseful elastically extensible materials include propylene basedhomopolymers or co-polymers, or ethylene based homopolymers orco-polymers selected from the group consisting of: an elastic randompoly(propylene/olefin) copolymer, an isotactic polypropylene containingstereoerrors, an isotactic/atactic polypropylene block copolymer, anisotactic polypropylene/random poly(propylene/olefin) copolymer blockcopolymer, a stereoblock elastomeric polypropylene, a syndiotacticpolypropylene block poly(ethylene-co-propylene) block syndiotacticpolypropylene tri-block copolymer, an isotactic polypropylene blockregion-irregular polypropylene block isotactic polypropylene tri-blockcopolymer, a polyethylene random (ethylene/olefin) copolymer blockcopolymer, a reactor blend polypropylene, a very low densitypolypropylene, a metallocene polypropylene, metallocene polyethylene,and combinations thereof. Additional non-limiting examples of usefulelastically extensible materials include styrene-isoprene-styrene blockcopolymers, styrene-butadiene-styrene block copolymers,styrene-ethylene-butylene-styrene block copolymers, polyurethanes,ethylene copolymers, polyether block amides, and combinations thereof.

The elastically extensible material may comprise modifying resins. Suchmodifying resins useful herein include, but are not limited to,unhydrogenated C5 hydrocarbon resins or C9 hydrocarbon resins, partiallyand fully hydrogenated C5 hydrocarbon resins or C9 hydrocarbon resins;cycloaliphatic resins; terpene resins; natural and modified rosins androsin derivatives; coumarone indenes; polycyclopentadiene and oligomersthereof; polymethylstyrene or oligomers thereof; phenolic resins; indenepolymers, oligomers and copolymers; acrylate and methacrylate oligomers,polymers, or copolymers; derivatives thereof; and combinations thereof.Modifying resins may also include alicyclic terpenes, hydrocarbonresins, cycloaliphatic resins, poly-beta-pinene, terpene phenolicresins, and combinations thereof. Useful C5 hydrocarbon resins and C9hydrocarbon resins are disclosed in U.S. Pat. No. 6,310,154.

The elastically extensible material may comprise a variety of additives.Suitable additives including, but not limited to, stabilizers,antioxidants, and bacteriostats may be employed to prevent thermal,oxidative, and bio-chemical degradation of the elastically extensiblematerial. Additives may account for about 0.01% to about 60% of thetotal weight of the elastically extensible material. In otherembodiments, the composition comprises from about 0.01% to about 25%. Inother suitable embodiments, the elastically extensible materialcomprises from about 0.01% to about 10% by weight, of additives.

The elastically extensible material may comprise various stabilizers andantioxidants that are well known in the art and include high molecularweight hindered phenols (i.e., phenolic compounds with sterically bulkyradicals in proximity to the hydroxyl group), multifunctional phenols(i.e., phenolic compounds with sulfur and phosphorous containinggroups), phosphates such as tris-(p-nonylphenyl)-phosphite, hinderedamines, and combinations thereof. Proprietary commercial stabilizersand/or antioxidants are available under a number of trade namesincluding a variety of Wingstay®, Tinuvin® and Irganox® products.

The elastically extensible material may comprise various bacteriostatsthat are known in the art. Examples of suitable bacteriostats includebenzoates, phenols, aldehydes, halogen containing compounds, nitrogencompounds, and metal-containing compounds such as mercurials, zinccompounds and tin compounds. A representative example is available underthe trade designation Irgasan Pa, from Ciba Specialty ChemicalCorporation of Tarrytown, N.Y.

The elastically extensible material may comprise viscosity modifiers,processing aids, slip agents or anti-block agents. Processing aidsinclude processing oils, which are well known in the art and includesynthetic and natural oils, naphthenic oils, paraffinic oils, olefinoligomers and low molecular weight polymers, vegetable oils, animaloils, and derivatives of such including hydrogenated versions.Processing oils also may incorporate combinations of such oils. Mineraloil may be used as a processing oil. Viscosity modifiers are also wellknown in the art. For example, petroleum derived waxes can be used toreduce the viscosity of the slow recovery elastomer in thermalprocessing. Suitable waxes include low number-average molecular weight(e.g., 0.6-6.0 kilo Daltons) polyethylene; petroleum waxes such asparaffin wax and microcrystalline wax; atactic polypropylene; syntheticwaxes made by polymerizing carbon monoxide and hydrogen such asFischer-Tropsch wax; and polyolefin waxes.

Elastomeric film 22 also includes at least one skin disposed on theelastically extensible material, the skin forming at least one of thefilm's surfaces 40, 44. Such skin is an extensible material and providesan outer surface to elastomeric film 22 that has less tackiness than theunderlying elastically extensible material. In some embodiments, theskin may also qualify as an elastically extensible material, but will beless elastic than the underlying elastically extensible material.

Accordingly, when compared to the elastically extensible material, theskin will have less recovery from the same amount of extension. Or inother words, when compared to the elastically extensible material, theskin will have a higher percentage set from the same percentage strain.The skin may aid in elastomeric film 22 processability and is betweenabout 1 μm and about 10 μm, or between about 3 μm and about 7 μm, or insome embodiments, is about 5 μm, in thickness. In certain embodiments,the skin that overlays the elastically extensible material inelastomeric film 22 is a polyolefin. Non-limiting examples of usefulskin materials include metallocene polyethylene, low densitypolyethylene, high density polyethylene, linear low densitypolyethylene, very low density polyethylene, a polypropylenehomopolymer, a plastic random poly(propylene/olefin) copolymer,syndiotactic polypropylene, metallocene polypropylene, polybutene, animpact copolymer, a polyolefin wax, and combinations thereof.

Exemplary elastomeric films that are useful in the stretch laminatesdetailed herein (i.e., an elastically extensible material with at leastone skin disposed on the surface of the elastically extensible material)include M18-1117 and M18-1361 elastomeric films commercially availablefrom Clopay Corporation of Cincinnati, Ohio; K11-815 and CEX-826elastomeric films commercially available from Tredegar Film Products ofRichmond, Va.; and elastomeric films commercially available from MondiGronau GmbH of Gronau, Germany. These exemplary elastomeric filmsinclude a single layer of elastically extensible material with a skindisposed on both surfaces of the material. Referring to FIG. 1A, suchexemplary elastomeric films would have a skin providing first surface 40and a second skin providing second surface 44. However, otherelastomeric films applicable to the stretch laminates detailed hereinonly need to have a skin that provides first surface 40 or secondsurface 44.

The cover layers 24, 26 may include a nonwoven material, including butnot limited to, spun only or spun meltblown combinations, such as SM(spunbond meltblown), SMS (spunbond meltblown spunbond), SMMS (spunbondmeltblown spunbond) nonwovens, SSMMS (spunbond meltblown spunbound),hydroentangled nonwovens and softbond nonwovens. The nonwoven materialsmay also include carded nonwovens, such as those specially designed andmanufactured to be compatible with an activation (e.g., ring-rolling)process. One exemplary nonwoven material is a carded nonwoven made froma polypropylene homopolymer. The spunbounds may also be speciallydesigned and/or manufactured to be compatible with an activationprocess. However, it is believed that through the use of the elastomericfilm according to the present disclosure, greater flexibility in thedesign choices may be achieved. For example, spunbounds may be selectedfor applications where only carded nonwovens were used in the past, orthinner elastomeric films may be used with the carded nonwovens. Otherimprovements in design flexibility will also be recognized by theskilled practitioner. For example, in some embodiments, the coverlayer(s) may be extensible nonwovens and may or may not need to undergoan activation process in order to impart extensibility to the stretchlaminate.

The basis weight of the nonwoven material may be less than about 30 gsm.In fact, according to certain embodiments, the basis weight may be lessthan about 27 gsm. In other embodiments, the basis weight may be lessthan about 25 gsm. In still other embodiments, the nonwoven material mayhave a basis weight of less than about 24 gsm. The nonwoven materialsmay also include additives, such as, for example, CaCO₃. Woven orknitted fabrics may also be used as cover layers 24, 26 in embodimentsof the stretch laminates detailed herein.

Adhesive 30, 32 may be selected from any adhesives known to providesuitable attachment between elastomeric film 22 and cover layers 24, 26.In some embodiments, the adhesive may be a hot melt adhesive with abasis weight of less than about 15 gsm. According to one embodiment, theadhesive may be H2031 adhesive commercially available from Bostik Inc.of Middleton, Mass. One characteristic of this adhesive is that, at 23°C., this adhesive has significant pressure-sensitive character usefulfor making a stretch laminate by hand. However, this adhesive is alsosuitable for use in fabricating stretch laminates from the elastomericfilms and cover layers listed above using conventional stretch laminatemanufacturing equipment, such equipment being well known in the art.

Elastomeric film 22 is mechanically pre-activated before attachment toat least one cover layer 24, 26. As further detailed in the STRETCHLAMINATE FABRICATION METHOD below, elastomeric film 22 may bepre-activated by being stretched transversely to its web direction bymore than 50% (i.e., strain >50%). In some embodiments, an expansion byabout 100% to about 500% occurs in relation to the starting width ofelastomeric film 22. In alternate embodiments, elastomeric film 22 maybe stretched in the web direction, stretched a direction other than theweb direction or transverse to the web direction, or a combination ofdirections. The term “stretching” is to point to the fact that theexpansion of elastomeric film 22 is not completely reversible and that anon-elastic fraction results in the film having a larger width followingpre-activation (i.e., the elastomeric film does not have 100% recovery,and therefore has a percent set value). After expansion, elastomericfilm 22 retracts and has a width that may be larger by about 10% toabout 30% in relation to a starting width of the film. In other words,after the pre-activation expansion and retraction detailed below,elastomeric film 22 may exhibit a set of about 10% to about 30%.

In addition, because elastomeric film 22 includes both an elasticallyextensible material and at least one skin disposed on the elasticallyextensible material, and because these materials have differentelasticity and recovery properties, the pre-activation process willphysically alter these materials differently. During pre-activation, theskin and the elastically extensible material are similarly stretched(i.e., put under similar strain). However, after stretching, the skinand the elastically extensible material will retract and recoverdifferently (i.e., have different set values). In comparison with theelastically extensible material, the skin is less elastic and thereforewill have less recovery after stretching, a.k.a., a higher set value.The skin is also much thinner than the elastically extensible material,so when the thicker elastically extensible material retracts andrecovers after pre-activation stretching, it will force the attachedskin to retract with it. But because the skin cannot recover as much asthe elastically extensible material, the skin buckles and wrinkles.Accordingly, the cross-sectional profile and the top view appearance ofelastomeric film 22 are modified after a pre-activation process.

FIGS. 2-5 are SEM photomicrographs of magnified cross-sections ofelastomeric films. These SEM photomicrographs, as well as the other SEMphotomicrographs included herein, were taken with a scanning electronmicroscope (Hitachi Model 3500). The information to calculate specificmagnifications and distances is included in each individual SEMphotomicrograph along the bottom of the frame. FIG. 2 is a SEMphotomicrograph taken at approximately 900× magnification showing across-sectional view of a portion of an elastomeric film that has notbeen pre-activated. The skins are the thin strips of contrastingmaterial at the top and the bottom of the cross-section, with thethicker elastically extensible material between the skins. The skin atthe top of the cross-section is easier to discern due to thecross-section being cut cleaner in that region. Without pre-activation,the skins, and thus the outer surfaces of the elastomeric film, aresubstantially smooth in a cross-sectional view. FIG. 3 is a highermagnification image (approx. 3500× magnification) of the skin at the topof cross-section shown in the SEM photomicrograph of FIG. 2.

FIG. 4 is a SEM photomicrograph taken at approximately 900×magnification showing a cross-sectional view of a portion of anelastomeric film that has been pre-activated. Again, the skins are thethin strips of contrasting material at the top and the bottom of thecross-section, with the thicker elastically extensible material betweenthe skins. With pre-activation, the skins, and thus the outer surfacesof the elastomeric film, are wrinkled in a cross sectional view. FIG. 5is a higher magnification image (approx. 3500× magnification) of theskin at the top off the cross-section shown in the SEM photomicrographof FIG. 4.

FIGS. 4 and 5 show that after pre-activation, the skin of elastomericfilm 22 includes a plurality of wrinkles having hills and furrows. Forexample, as shown in the non-limiting sample photographed in FIG. 5,there are approximately six hills and six furrows of varying size withinthe pictured approximately 35 μm of length taken along thecross-sectional profile of the pre-activated elastomeric film. This isin comparison to FIG. 3, in which there are no hills and no furrowswithin the pictured approximately 35 μm of length taken along thecross-sectional profile of an elastomeric film that was notpre-activated. However, as visible on the top surface of the elastomericfilm shown in FIG. 3, one or more random hills and/or furrows may bepresent within a particular length of cross-sectional profile of anelastomeric film that was not pre-activated. These random hills and/orfurrows are due to irregularities in the surface of the elastomericfilm. Such random hills and/or furrows should not be confused with thehills and furrows of the plurality of wrinkles that are intentionallyformed in an elastomeric film through a mechanical pre-activationprocess.

FIGS. 6 and 7 are transmitted light photomicrographs of magnified topviews of elastomeric films. The transmitted light photomicrographs weretaken in color using a Nikon SMZ 1500 Stereo Light Microscope equippedwith an Evolution Mp5C Digital camera with white light shiningunderneath the elastomeric film samples. The blue scale marks at thebottoms of FIGS. 6 and 7 are in millimeters. This scale can be used tocalculate specific magnifications and distances in the transmitted lightphotomicrographs. FIG. 6 is a transmitted light photomicrograph showinga top view of a portion of an elastomeric film that has not beenpre-activated. Without pre-activation, the viewable outer surface of theelastomeric film (i.e., the top view of the skin), has no discerniblestripes and is uniform in appearance. FIG. 7 is a transmitted lightphotomicrograph showing a top view of a portion of an elastomeric filmthat has been pre-activated. With pre-activation, the top view of theskin includes a plurality of stripes in varying thicknesses that relateto the size and pitch of the intermeshing discs of the mechanicalpre-activation means (as further detailed in the STRETCH LAMINATEFABRICATION METHOD below). The stripes, referred to herein as activationstripes, indicate zones in the pre-activated elastomeric film in whichthere was a particular range of stretching during the pre-activationprocess. For example, as shown in non-limiting sample photographed inFIG. 7, there are medium thickness darker blue stripes indicative of aheavier intensity skin wrinkling, large thickness light blue stripesindicative of medium intensity skin wrinkling, and thin white stripesindicative of lower intensity skin wrinkling.

In addition, after preactivation, but before utilizing elastomeric film22 in the fabrication of stretch laminate 20, the film may optionally beprinted with an image or motif that may show through the cover layers ofthe stretch laminate. The ink or other pigment utilized in printing willbe deposited on the hills and into the furrows of the wrinkles of thepre-activated elastomeric film. Ink deposited onto the textured surfaceof a pre-activated elastomeric film allows for more contact surface areabetween the elastomeric film and the ink. Accordingly, when printing ona pre-activated elastomeric film, there is an image that is morestrongly set on the film when compared to an image printed on the muchsmoother surface of an elastomeric film that has not been pre-activated.

Moreover, when stretch laminate 20 includes a pre-activated (andsubsequently printed) elastomeric film that is mechanically activated(as further detailed in the STRETCH LAMINATE FABRICATION METHOD below),a non-distorted printed image on the film is evenly and reversiblystretched along with it. This is because before the image was printed onthe pre-activated elastomeric film, a significant portion, or theentire, non-elastic fraction of elastomeric film 22 has already beenremoved in the pre-activation process. In other words, the set had beenremoved from elastomeric film 22 before printing. Therefore, the printedimage will not substantially distort further with the later activationof stretch laminate 20, or in additional stretching of the laminate by auser. In contrast, if an image or motif were printed on an elastomericfilm that was not pre-activated, and that printed film was then used infabricating a stretch laminate, and then the stretch laminate wasmechanically activated, the desired image would be distorted in thefinal activated stretch laminate. This is because the set of theelastomeric film was not removed prior to the printing process, and suchset would be removed from the elastomeric film in the mechanicalactivation of the fabricated stretch laminate, thus distorting theoriginal printed image. Likewise, if an elastomeric film is printed andthen subsequently preactivated, the set of the elastomeric film will notbe removed prior to the printing process, and such set would be removedfrom the elastomeric film in the pre-activation process, thus distortingthe original printed image.

And in another embodiment, a pre-activated elastomeric film may bestretched again during the printing of the film. The printed film isthen relaxed and used in fabrication and activation of the stretchlaminate. The resulting activated stretch laminate has an image or motifthat is aesthetically pleasant when the stretch laminate is in astretched condition during use (e.g., when a user stretches the stretchlaminate in application or removal of an absorbent article).

In fabricating stretch laminate 20, cover layers 24, 26 are attached toelastomeric film 22 through the use of adhesives 30, 32. When utilizingan elastomeric film that has not been pre-activated, the adhesive has arelatively smooth surface in which to adhere. FIG. 8 is a SEMphotomicrograph taken at approximately 900× magnification showing across-sectional view of a portion of a stretch laminate that includes anelastomeric film that has not been pre-activated. The skin is the thincontrasting strip of material running about midway through thephotomicrograph, with the thicker elastically extensible material belowthe skin. Disposed on top of the skin is an adhesive, which is alsoattached to the cover layer. In this exemplary embodiment, the fibers ofthe cover layer are the large cylindrical objects at the top of the SEMphotomicrograph. Without pre-activation, the skins, and thus the outersurfaces of the elastomeric film, are substantially smooth in across-sectional view. FIG. 9 is a higher magnification image (approx.3500× magnification) of the interaction between the skin and glue asshown in the SEM photomicrograph of FIG. 8.

FIG. 10 is a SEM photomicrograph taken at approximately 900×magnification showing a cross-sectional view of a portion of a stretchlaminate that includes an elastomeric film that has been pre-activated.The skins are the contrasting strips of material running through themiddle of the photomicrograph, with the thicker elastically extensiblematerial between the skins. With pre-activation, the skins, and thus theouter surfaces of the elastomeric film, are wrinkled in a crosssectional view. Disposed on outer surfaces of the skin (i.e., thesurfaces not contacting the elastically extensible material) isadhesive, which is also attached to the cover layer. In this exemplaryembodiment, the fibers of the cover layer are the large cylindricalobjects at the top and bottom of the SEM photomicrograph. Thepre-activated elastomeric film includes a textured skin with wrinkles ina cross-sectional view. FIG. 11 is a higher magnification image (approx.3500× magnification) of the skin at the top of the elastomeric filmshown in the SEM photomicrograph of FIG. 10.

As previously shown in FIGS. 4 and 5, FIGS. 10 and 11 also illustratethat after pre-activation, the skin of elastomeric film 22 is texturedand includes a plurality of wrinkles having hills and furrows. Adhesive30, 32 that attaches elastomeric film 22 to cover layers 24, 26 may flowover the hills and into the furrows of the pre-activated elastomericfilm. Accordingly, adhesive 30, 32 is disposed in the furrows of theskin of elastomeric film 22. This is in comparison to FIGS. 8 and 9, inwhich there are no furrows in the elastomeric film for the adhesive toflow into. Adhesive flowing into the furrows of a pre-activatedelastomeric film allows for more contact surface area between the filmand the adhesive, leading to a stronger bond between the cover layer andthe film. Accordingly, when using the same amount of adhesive, there isa stronger bond (e.g., better creep resistance) between a pre-activatedelastomeric film and a cover layer when compared to the bond between anelastomeric film that has not been pre-activated and a cover layer.Moreover, when employing a pre-activated elastomeric film, previous bondstrengths between elastomeric films that were not pre-activated and acover layer may be achievable with the use of less adhesive.

In embodiments of stretch laminates that include a elastomeric film thatis pre-activated and subsequently printed, the ink or other pigmentutilized in printing will be deposited on the hills and into the furrowsof the wrinkles of the film. As detailed above, ink deposited onto thetextured surface of a pre-activated elastomeric film will more stronglyset on the film due to the additional contact surface area between theelastomeric film and the ink (in comparison to ink disposed on aelastomeric film that has not been pre-activated). Adhesive 30, 32 thatattaches elastomeric film 22 to cover layers 24, 26 may also flow overthe hills and into the furrows of the pre-activated elastomeric film.Accordingly, adhesive 30, 32 is disposed over the ink and/or in thefurrows of the skin of pre-activated elastomeric film 22. And becausethe ink is more strongly set on the pre-activated elastomeric film, whenusing the same amount of adhesive, there is a stronger bond (e.g.,better creep resistance) between a pre-activated (and subsequentlyprinted) elastomeric film and a cover layer when compared to the bondstrength between an printed elastomeric film that has not beenpre-activated and a cover layer. Moreover, when employing apre-activated (and subsequently printed) elastomeric film, previous bondstrengths between printed elastomeric films that were not pre-activatedand a cover layer may be achievable with the use of less adhesive.

In addition, pre-activating an elastomeric film also lowers the forceneeded to later stretch the film (versus a non-activated film). Thishelps the later mechanical activation of the stretch laminate (asfurther detailed in the STRETCH LAMINATE FABRICATION METHOD below)because the load required to activate a stretch laminate that is madewith pre-activated film will be lower (versus a non-activated film).

Exemplary Ear Panel and Absorbent Article

Having thus described the stretch laminate above, the use of the stretchlaminate in a side panel of an absorbent article is now detailed.Specifically, the exemplary embodiment below details an ear panelportion of a side panel that is fabricated from a stretch laminatedetailed herein. In addition to use in side panels as detailed below,the stretch laminates described herein may also be used in otherportions of the side panels of pants diapers and taped diapers. Further,while use of the stretch laminate is suggested in regard to certainregions of the absorbent article, it will be recognized that the stretchlaminate may be used in other regions as well.

FIG. 12 is a top view of an exemplary disposable absorbent article 120in its flat, uncontracted state (i.e., without elastic-inducedcontraction). Portions of disposable absorbent article 120 have been cutaway to more clearly show the underlying structure of the article. Asillustrated, the portion of disposable absorbent article 120 thatcontacts the wearer faces the viewer (i.e., showing the interior orinner side of the article). Disposable absorbent article 120 has alongitudinal axis 130 and a transverse axis 132.

One end portion of disposable absorbent article 120 is configured as afirst waist region 140 of the article. The opposite end portion isconfigured as a second waist region 142 of disposable absorbent article120. Waist regions 140 and 142 generally comprise those portions ofdisposable absorbent article 120 which, when worn, encircle the waist ofthe wearer. Waist regions 140 and 142 may include elastic elements suchthat they gather about the waist of the wearer to provide improved fitand containment. An intermediate portion of disposable absorbent article120 is configured as a crotch region 144, which extends longitudinallybetween first and second waist regions 140, 142. Crotch region 144 isthat portion of disposable absorbent article 120 which, when the articleis worn, is generally positioned between the legs of the wearer.

Disposable absorbent article 120 has a laterally extending first waistedge 150 in first waist region 140 and a longitudinally opposing andlaterally extending second waist edge 152 in second waist region 142.Disposable absorbent article 120 has a first side edge 154 and alaterally opposing second side edge 156, both side edges extendinglongitudinally between first waist edge 150 and second waist edge 152.The portion of first side edge 154 in first waist region 140 isdesignated 154 a, the portion in crotch region 144 is designated 154 b,and the portion in second waist region 142 is designated 154 c. Thecorresponding portions of second side edge 156 are designated 156 a, 156b, and 156 c, respectively.

Disposable absorbent article 120 preferably comprises a water-permeabletopsheet 160, a water-impermeable backsheet 162, and an absorbentassembly or core 164, which may be disposed between the topsheet and thebacksheet, with the topsheet attached to the backsheet. Topsheet 160 maybe fully or partially elasticized or may be foreshortened. Exemplarystructures including elasticized or foreshortened topsheets aredescribed in greater detail in U.S. Pat. Nos. 4,892,536; 4,990,147;5,037,416; and 5,269,775, among others.

Disposable absorbent article 120 may include at least one elastic waistfeature 170 that helps to provide improved fit and containment. Elasticwaist feature 170 may be intended to elastically expand and contract todynamically fit the wearer's waist. Elastic waist feature 170 may extendat least longitudinally outwardly from at least one waist edge (e.g.,edge 150) of absorbent article 150 and generally forms at least aportion of the waist region (e.g., region 140) of absorbent article 120.Diapers are often constructed so as to have two elastic waist features170, 172, one (170) positioned in first waist region 140 and one (172)positioned in second waist region 142. Further, elastic waist feature170, 172 may be made of stretch laminate 20 attached or joined tobacksheet 162. Alternatively, elastic waist feature 170, 172 may beconstructed as an extension of other elements of the absorbent article,such as topsheet 160, backsheet 162, or both the topsheet and thebacksheet (e.g., topsheet 160 or backsheet 162 defines one of the coverlayers 24, 26 of stretch laminate 20). Other elastic waist featureconstructions are described in U.S. Pat. Nos. 4,515,595; 4,710,189;5,151,092; and 5,221,274.

Disposable absorbent article 120 may include side panels 180, 182attached to backsheet 162. In some embodiments, side panels 180, 182 mayinclude ear panels 184. As detailed above, one or more of the sidepanels 180, 182, or particular portions of such side panels such as earpanels 184, may be elastically elongatable panels made from stretchlaminate 20. This construction may provide a more comfortable andcontouring fit by initially conformably fitting disposable absorbentarticle 120 to the wearer, and sustaining this fit throughout the timeof wear well past when the article has been loaded with body wastes,insofar as elasticized side panels 180, 182 allow the sides of thearticle to expand and contract. Side panels 180, 182 may also providemore effective application of disposable absorbent article 120 becauseeven if the caretaker pulls one elasticized side panel 180 farther thanthe other (182) during application, the absorbent article 120 will“self-adjust” during wear. While disposable absorbent article 120preferably has side panels 180, 182 disposed in second waist region 142,the article may be provided with side panels disposed in first waistregion 140, or in both front waist region 140 and second waist region142.

Disposable absorbent article 120 may include fasteners 190 disposed onear panels 184. Fasteners 190 may also be disposed directly on theinterior of the article in second waist region 142 adjacent to portion154 c of first side edge 154 and adjacent to portion 156 c of secondside edge 156. Fasteners 190 may be formed of any material and in anyform that will releasably attach to the mating surface of the opposingwaist region when pressed against it. For example, the primary fasteningcomponent may be a mechanical fastener that releasably engages with themating surface, such as by means of a plurality of hooks engaging withloops formed by fibers in a nonwoven sheet. Alternatively, the primaryfastening component may be an adhesive that releasably adheres to themating surface. In fact, the fasteners may include tape tabs, hook andloop fastening components, interlocking fasteners such as tabs & slots,buckles, buttons, snaps, and/or hermaphroditic fastening components.Exemplary surface fastening systems are disclosed in U.S. Pat. Nos.3,848,594; 4,662,875; 4,846,815; 4,894,060; 4,946,527; 5,151,092; and5,221,274, while an exemplary interlocking fastening system is disclosedin U.S. Pat. No. 6,432,098. The fastening system may also includeprimary and secondary fastening systems, as disclosed in U.S. Pat. No.4,699,622. Additionally exemplary fasteners and fastener arrangements,the fastening components forming these fasteners, and the materials thatare suitable for forming fasteners are described in U.S. PublishedApplication Nos. 2003/0060794 and 2005/0222546 and U.S. Pat. No.6,428,526.

Still other variations are also possible. For example, fasteners 190 maybe disposed on the interior of disposable absorbent article 120 in firstwaist region 140 such that first waist region 140 overlaps second waistregion 142 when they are fastened together. As another example,fasteners 190 may be disposed on the exterior of disposable absorbentarticle 120 rather than on the interior. As a further example, fasteners190 may be used with a specific mating fastener surface particularlysuited for cooperation with the fasteners (e.g., a loop layer that workswith a hook fastener, or a layer particularly treated to provide asuitable contacting surface for a specific adhesive).

FIG. 13 depicts disposable absorbent article 120 configured to as itwould be during use. Portion 154 c of side edge 154 is shown in an opencondition, such as prior to closing and fastening or after beingreopened. Portion 156 c of opposing side edge 156 is shown fastened.Second waist region 142 overlaps first waist region 140 when they arefastened together. Alternatively, disposable absorbent article 120 mayalso include permanent or refastenable side seams that can be used tofasten the waist regions together. According to one exemplaryembodiment, the side seams may include fasteners (or another form ofattachment) that can be used to configure the article like a pair ofpull-on training pants or disposable pants.

FIG. 14 illustrates a top view of an exemplary embodiment of ear panel184 that is fabricated out of stretch laminate 20 that has beenmechanically activated. Ear panel 184 has a first longitudinallyoutermost lateral edge 50, a second longitudinally outermost lateraledge 51, an inboard end 52 and an outboard end 53. A stretch zone 66 ofstretch laminate 20 is mechanically activated and is elasticallyextensible along a stretch direction 67. Stretch zone 66 may extendbetween inboard stretch zone extent 86 and outboard stretch zone extent87. Stretch zone extents 86, 87 may fall along inboard and outboardlines at which a region of mechanical activation is bounded. Borderingstretch zone 66 are anchoring zones 68, 69. Anchoring zone 68 may extendbetween inboard stretch zone extent 86 and inboard anchoring zone extent88. Anchoring zone 69 may extend between outboard stretch zone extent 87and outboard anchoring zone extent 89. Anchoring zones 68, 69 of stretchlaminate 20 are not mechanically activated.

Fastener 190 may be integrally formed with ear panel 184, or formed froma separate material. In embodiments where fastener 190 is formed from aseparate material, the fastener may be attached to the ear panel 184 ata fastener attachment zone 71, which may be bounded by outboard end 53and outboard stretch zone extent 87. The fastener may be attached to earpanel 184 in any suitable manner, including, but not limited to,continuous or intermittent adhesive bonding, compression bonding, heatbonding, ultrasonic bonding, combinations thereof, etc. Ear panel 184may be integrally formed with a side panel, or formed from a separatematerial. In embodiments where ear panel 184 is formed from a separatematerial, the ear panel may be attached to the side panel at an earpanel attachment zone 70, which may be bounded by inboard end 52 andinboard stretch zone extent 86. Ear panel 184 may be attached to a sidepanel in any suitable manner, including, but not limited to, continuousor intermittent adhesive bonding, compression bonding, heat bonding,ultrasonic bonding, combinations thereof, etc.

As further detailed in the STRETCH LAMINATE FABRICATION METHOD below,stretch laminate 20 is mechanically activated by stretching the laminatetransversely in relation to the direction of the web. The technique forforming such a stretch laminate is generally referred to as “zerostrain” stretch laminate formation. Examples of zero strain stretchlaminate formations and the resulting stretch laminates are described inU.S. Pat. Nos. 4,116,892; 4,834,741; 5,143,679; 5,156,793; 5,167,897;5,422,172; and 5,518,801. In the particular zero strain stretch laminateformation detailed herein, stretch laminate 20 may be guided through anip between two profile rollers, each roller including at least two diskpackets having a plurality of intermeshing disks that are situated on anaxis. This process is also commonly referred to as a “ring rolling”process. Stretch laminate 20 is transversely stretched in places by theintermeshing disk packets. The region in which stretch laminate 20 isstretched by the intermeshing disk packets is referred to as stretchzone 66. In the roller sections between and/or outside the disk packets,the profile rollers form a gap, through which stretch laminate 20 isguided though essentially without transverse stretching. The regions inwhich stretch laminate 20 are not stretched by the intermeshing diskpackets are referred to as anchoring zones 68, 69.

In stretch zone 66, the fibers of cover layers 24, 26 are modified andirreversibly stretched due to fiber tears and rearrangements. However,because stretch laminate 20 includes elastomeric film 22 that has beenpre-activated, the elastomeric film between the cover layers is notfurther substantially stretched during the mechanical activation process(i.e., a substantial amount of set is not added to the film duringactivation of the stretch laminate). In other words, elastomeric film 22has substantially the same transverse width before and after mechanicalactivation of stretch laminate 20. This is because a significant portion(or the entire) non-elastic fraction of elastomeric film 22 (i.e., theset value) has already been removed in the pre-activation process.Accordingly, the expansion property of the fabricated stretch laminate20 is improved in stretch zones 66 in the cross-direction (i.e.,transverse in relation to the longitudinal web direction) due tomechanical activation. Following activation, when applying minimalforce, stretch laminate 20 is easily expandable in the cross-direction.

Thus, in mechanically activated stretch laminate 20 (as used tofabricate ear panel 184 and other absorbent article parts), elastomericfilm 22 is activated in both stretch zone 66 and anchoring zones 68, 69.In previous stretch laminates that did not include a pre-activatedelastomeric film, the mechanically activated stretch laminate wouldinclude an elastomeric film that was activated in stretch zone 66, butnot activated in anchoring zones 68, 69. Accordingly, the portion of theelastomeric film that was located in the anchoring zones did not containa plurality of wrinkles. Also, when the viewed from the top, the portionof the elastomeric film that was located in the anchoring zones did notinclude a plurality of activation stripes. Further, in previous stretchlaminates that did not include a pre-activated elastomeric film, theadhesive bonding the elastomeric film to the cover layers was in contactwith a non-wrinkled surface on the surface of the film located in bothstretch zone 66 and anchoring zones 68, 69 during fabrication. Instretch laminate 20 described herein, adhesive 30, 32 that bondselastomeric film 22 to cover layers 24, 26 is in contact with a texturedsurface having a plurality of wrinkles on the surface of the filmlocated in both stretch zone 66 and anchoring zones 68, 69 duringfabrication, providing for increased bond strength between the film andthe cover layers.

Stretch Laminate Fabrication Method

The schematic illustration of FIG. 15 details an exemplary embodiment ofa method for fabricating the stretch laminates detailed herein. Themethod includes providing and pre-activating an elastomeric film 1 (asdetailed in the STRETCH LAMINATE section above). Elastomeric film 1 ismechanically pre-activated by stretching the film transverse to its webdirection by more than 50%. In some embodiments, an expansion by about100% to about 500% occurs in relation to the starting width ofelastomeric film 1. The term “stretching” is to point to the fact thatthe expansion of elastomeric film 1 is not completely reversible andthat a non-elastic fraction results in the film having a larger widthfollowing retraction (i.e., reverse expansion). After expansion,elastomeric film 1 retracts and has a width B₂ that is larger by about10% to about 30% in relation to a starting width B₁ of the film.Accordingly, elastomeric film 1 has a set of about 10% to about 30%resulting from the pre-activation process.

For the pre-activation process, elastomeric film 1 may be guided througha system of intermeshing profile rollers, each roller including diskpackets having a plurality of intermeshing disks that are situated on anaxis (i.e., a ring rolling process). Elastomeric film 1 is transverselystretched by the intermeshing disk packets. The stretching may beuniform or varied over the width of the film. The pre-activation processcan be carried out at varying pitch and or varying depths of engagement.The pre-activation process can also be carried out in machine direction,or in any other direction. The pre-activation of elastomeric film 1 hasa positive effect on the stretching force profile and helps allow for aneasy stretching action of the fabricated stretch laminate over a largeexpansion area. Further, the recovery of the stretch laminate can alsobe improved by pre-activating elastomeric film 1. The recovery is theability of a stretch laminate to return to original size after it hasbeen stretched to its expansion limit. The increased recovery ofelastomeric film 1 after the pre-activation process is due to theremoval of an amount of set from the film.

After preactivation, but before cutting elastomeric film 1 into filmstrips 2, the film may optionally be printed in a printing station 11with an image or motif that may show through the cover layers of thestretch laminate. Any known continuous printing methods can be used forprinting the elastomeric film 1. Non-limiting exemplary printing methodsinclude digital printing, inkjet printing, and rotary printing methods,in particular, flexography. As a non-limiting example, the printed imageor motif can be a striped motif made of parallel colored stripes thatextend in the web's longitudinal direction of elastomeric film 1.

The pre-activated, and optionally printed, film is then cut into filmstrips 2. The film strips 2 are guided across redirecting means 3 andsupplied to laminating means 4 as parallel strips. Film strips 2 arethen laminated in laminating means 4 between cover layers 5, 6 (asdetailed in the STRETCH LAMINATE section above), which are suppliedabove and below the film strips. Film strips 2 and cover layers 5, 6 maybe glued together or connected to each other by thermal means to formcomposite material 7 (i.e., an embodiment of the stretch laminatematerials detailed herein). As illustrated in FIG. 15, film strips 2 arelaminated at a distance relative to each other between cover layers 5,6. Cover layers 5, 6 are therefore directly connected to each other inthe regions between film strips 2. Accordingly, elastic regions 8, aswell as non-elastic regions 9, are created in composite material 7. Thedistance between film strips 2 can be adjusted by positioning theredirecting means. It is also contemplated that reinforcement strips maybe laminated between film strips 2 to reinforce non-elastic regions 9between the film strips.

Composite material 7 is then supplied to an activation means 10 in whichthe composite material is stretched at portions of elastic regions 8transversely in relation to the direction of the web. For thestretching, composite material 7 may be guided through a nip between twoprofile rollers, each roller including at least two disk packets havinga plurality of intermeshing disks that are situated on an axis.Composite material 7 is transversely stretched in places by theintermeshing disk packets. The regions in which composite 7 is stretchedby the intermeshing disk packets are referred to as stretch zones. Inthe roller sections between and/or outside the disk packets, the profilerollers form a gap, through which composite 7 is guided thoughessentially without transverse stretching. The regions in whichcomposite 7 is not stretched by the intermeshing disk packets arereferred to as anchoring zones. In the stretch zones, the fibers ofcover layers 5, 6 are modified and irreversibly stretched due to fibertears and rearrangements. Accordingly, the expansion property ofcomposite material 7 is improved in the stretch zones in the crossdirection (i.e., transverse in relation to the longitudinal webdirection). Following activation, when applying minimal force, compositematerial 7 is easily expandable in the cross direction to an expansionlimit that is preset by the stretching of activation means 10.

When traditional nonwovens are utilized as the cover layers, anypre-activation of elastomeric film 1 cannot replace but can onlysupplement the mechanical activation of composite material 7.Accordingly, even when elastomeric film 1 is pre-activated, it is stillnecessary for composite material 7 to be stretched transversely relativeto the direction of the web in the regions that are to be renderedelastic via laminated elastomeric film strips (i.e., stretch zones).However, there may be some embodiments of composite material 7 that useextensible nonwovens as the cover layers, and therefore it may not benecessary to activate the composite material.

In fabrication of the printed stretch laminate embodiments that aredisclosed herein, elastomeric film 1 is printed with an image or motif,which shows through at least one of the cover layers 5, 6 of compositematerial 7. Due to the fact that elastomeric film 1 is provided with theimprint, correct alignment of the printed motif relative to the elasticregion of composite material 7 is always ensured. In addition, whenstretching composite material 7, the printed image is evenly andreversibly stretched along with it. Furthermore, the printed motif mayshow through on the front side as well as on the back side of compositematerial 7, such that the composite material is optically equallyattractive on the front as well as the back side thereof.

Test Methods T-Peel Test

For each of the sample preparations described below, the adherent andadherend must be handled with care to avoid contact with hands, skin, orother contaminating surfaces. Clean sheets of untreated paper may beused to protect the surfaces of the adherent and adherend during thesample preparation. This method is used to determine the T-Peel strengthof the bond formed between an adherent and an adherend with adhesive inbetween.

Sample Preparation—The sample preparation for the T-peel test will varybased on whether the material is available as a discrete web or isincorporated in a product.For materials as a discrete web: FIGS. 16 and 17 illustrate a bondedsample formed according to the directions provided below. FIG. 17 is across-sectional view taken along sectional line 17-17 of FIG. 16.

For a receiving sample 812 having a proximal edge 840, an adherend 814(i.e., film either pre-activated or unactivated) is resized usingcutting dies to create rectangular receiving samples with the dimensionsof 7.62 cm (3″) wide in material cross direction (perpendicular tomachine direction) and 20 cm (7.9″) long in material machine direction.The material that forms the adherend 814 is to be free of pleats (i.e.,areas in which the adherend 814 folds or creases onto itself). Theadherend 814 is elastomeric, hence the receiving sample is backed withlike sized piece of poly(ethylene terephthalate) film (PET film, 200gauge, X-Clear) 810 using double sided tape (such as FT 239 availablefrom Avery Denninson Corp., Painesville, Ohio or 9589 available from 3M,St. Paul, Minn.). The bonded sample is rolled with a 4.5 pound (2 kg)HR-100 ASTM 80 shore rubber-faced roller (2″ wide), rolled one time overthe entire bonded area. The bonded sample is to be free of pleats (i.e.,areas in which the bonded sample folds or creases onto itself).

Adhesive H2861 available from Fuller is sprayed in spiral pattern at 7gsm basis weight on release paper (such as a double sided siliconecoated paper available as supplier code HV100-473/473 from Fox RiverAssociates, LLC., Geneva, Ill.). Spirals are sprayed in ˜12 mm diameterat frequency of 3 spirals per mm in machine direction length, andadjacent to each other with minimum (<1 mm) overlap. A sheet of suchglue sprayed release paper in dimension of 7.62 cm in machine directionand 20 cm in cross direction is cut. The cut sample with the adhesiveside facing the adherend 814 is applied on top of the adherend 814,which is backed with PET film 810. The bonded sample is rolled with a4.5 pound (2 kg) HR-100 ASTM 80 shore rubber-faced roller (1.75″ wide),rolled one time across sample width. The release paper from the bondedsample is then pulled off, leaving glue layer 816 on adherend 814. Suchcreated receiving sample 812 is used for bonding with engaging sample822 described below. It should be appreciated that the receiving sample812 can be created with larger sized materials and then resized to 7.62cm×20 cm.

For the engaging sample 822, a 7.62 cm (3″) wide×20 cm (7.9″) long pieceof an adherent 828, which is poly (ethylene terephthalate) film, isused. The adherent 828 is to be free of pleats (i.e., areas in which theadherent 828 folds or creases onto itself).

The engaging sample 822 is bonded to the receiving sample 812 with theadhesive on the bonding surface. Bonding is to be performed on a flat,clean, rigid surface such as a countertop. The engaging sample 822 isapplied to the adhesive layer 816 on receiving sample 812 so as to avoidpleats in the sample. The adhesive layer 816 is centered on the adherent828 with the longitudinal edges of the adherent 828 being substantiallyparallel to the longitudinal edges of the adherend 814 and adhesivelayer 816. The proximal edge 840 of the receiving sample 812 is alignedwith the proximal edge 842 of the engaging sample 822. The receivingsample 812 and engaging sample 822 should each extend at least 25millimeters beyond the bonded portion of the samples such that theproximal edge 840 of the receiving sample 812 and the proximal edge 842of the engaging sample 822 can be easily placed in the test instrument'sgrips. A small piece of release paper 830 (such as a double sidedsilicone coated paper available as supplier code HV100-473/473 from FoxRiver Associates, LLC., Geneva, Ill.) is placed between the adhesivelayer 816 (adjacent the proximal edge 840) and the adherent 828(adjacent the proximal edge 842). The release paper 830 is inserted afew millimeters between the 816 and the 828 layers (i.e., no more than10% of the total bonded length). The bonded sample is rolled with a 11lb steel faced roller that is 2.25″ wide (4983 GR, RDL-0960-1, J-2004).Two full strokes (i.e., back and forth) are applied across the sample ata speed of approximately 10 mm/sec. Strokes are repeated over theremaining width of the sample, since width of the rubber (2.25″) is lessthan the width of the sample (3″). The bonded area should beapproximately 7.62 cm (3″) wide by 20 cm (7.9″) long (i.e., the samearea as the engaging sample).

For the T-Peel test, a 2.54 cm (1″) wide by 20 cm (7.9″) long sample iscut from the bonded sample using die cut. This sample is then peeledusing the method described below.

A skilled artisan should recognize that bonded specimens of otherdimensions may be used in the T-Peel Method. The dimensions of thereceiving and engaging members may vary from those listed above;however, the effective bonding area should be used to normalize theresultant T-Peel force recorded per inch of bonded width (i.e., thebonded width being the width of the bonded area measured substantiallyparallel to the grip width once the sample is mounted in the tensiletester).

Materials Incorporated in a Product:

Materials that are pre-bonded in a product are taken as a preparedsample. To perform the T-peel test, the bonded material is cut from theproduct, if possible. However, if the adherend (wrinkled film in thiscase), and/or adherent are joined to other materials in a face-to-faceconfiguration, the face-to-face configuration between the adherend andthe other material or adherent and the other material should bemaintained. Removal of the materials from the product should be done topreserve the integrity of the materials (e.g., adherend and adherentshould not be permanently deformed or should not be debonded from eachother). Before loading the samples for T-peel test, the receiving andengaging surfaces should be separated approximately 1-5 mm to initiatethe peeling. The portion of the sample including the adherend is thereceiving sample 812, and the portion of the sample including theadherent is the engaging sample 822. The receiving sample 812 andengaging sample 822 should each extend at least 25 millimeters beyondthe bonded portion of the samples such that the proximal edge 840 of thereceiving sample 812 and the proximal edge 842 of the engaging sample822 can be easily placed in the test instrument's grips. The T-peel testshould be performed on the bonded materials as described in the methodbelow. A skilled artisan should recognize that peel angle can affect thepeel force. During peeling, the peel angle should be maintained around180 degrees (i.e., adherent and adherend pulled directly away from eachother). Furthermore, if the adherent or adherend are elastomeric, theadherent or adherend must be backed with a similar sized sheet of 2 mil(0.05 mm) PET film in order to prevent stretching of the testedsubstrate.

Test Conditions—

The T-Peel test method is performed in a controlled room at 22° C.+/−2°C. and RH 50%+/−10%. Suitable instruments for this test include tensiletesters commercially available from Instron Engineering Corp., Canton,Mass. (e.g. Instron 5564) or from MTS Systems Corp., Eden Prairie, Minn.(e.g. Alliance RT/1 or Sintech 1/S). The following procedure illustratesthe measurement when using the Instron 5564. The instrument isinterfaced with a computer loaded with the Instron® Merlin™ MaterialTesting Software which controls the testing parameters, performs dataacquisition and calculation, and provides graphs and data reports. Theinstrument is configured with a data acquisition speed of 50 Hz. Anyresulting graphs are plotted using the Average Value (integral) settingon the instrument. A load cell is selected so that the forces to bemeasured will be between 10% and 90% of the capacity of the load cell orthe load range used (e.g., typically, a 10N to 100N load cell). Theinstrument is calibrated to an accuracy of at least 0.1% according tothe manufacturer's instructions. The instrument has two grips: astationary grip and a movable grip. The grips used are wider than thesample; typically, 2 inch (5.08 cm) wide grips are used. The grips areair-actuated grips and designed to concentrate the entire gripping forcealong a plane perpendicular to the direction of testing stress. Thedistance between the lines of the gripping force (i.e., gauge length) isset to 1″ (2.54 cm). The load reading on the instrument is zeroed toaccount for the mass of the fixture and grips. The bonded sample ismounted so that the proximal edge 840 of the receiving sample 812 is inthe movable grip and the proximal edge 842 of the engaging sample 822 isin the stationary grip. The bonded sample is mounted such that there isa minimum amount of slack in the receiving sample 812 or engaging sample822 between the grips. The specimen is mounted into the grips in amanner such that there is no slack and the load measured is between 0.00Newton and 0.02.

The receiving sample 812 is separated from the engaging sample 822 usinga crosshead speed of 12 inches/min (305 mm/min). An average load iscalculated as the average load between about 1″ (about 25 mm) and about6.26″ (about 160 mm) displacement. For samples that do not meet thedimensions provided in the Sample Preparation, the average load iscalculated from the loads acquired from the crosshead extension betweenabout 25% to about 87.5% of the sample length. For example, if thesample is 4″ long, the average load is calculated between about 1 inches(2.54 cm) to 3.5″ length of the sample. The average load is normalizedas follows: normalized load (N/cm)=average load initial bond width incentimeters. For 1″ wide sample, average load is divided by 2.54 cm toget normalized load. N=at least 3 samples evaluated to get good averagepeel.

Hysteresis (% Set) Test:

This method is used to determine properties of elastomers, including theform of flat films, which may correlate with the growth in productdimension experienced during the processing of the product containingthe elastomeric composition. The hysteresis test method is performed atroom temperature (22-25° C.). The material to be tested is cut into asubstantially rectilinear shape in the material's cross direction.Sample dimensions should be selected to achieve the required strain withforces appropriate for the instrument. Suitable sample dimensions areapproximately 25.4 mm wide (in the direction perpendicular tostretching, machine direction) by approximately 76.2 mm long (in thedirection of stretching, cross direction). Suitable instruments for thistest include tensile testers from MTS Systems Corp., Eden Prairie, Minn.(e.g. Alliance RT/1 or Sintech 1/S) or from Instron Engineering Corp.,Canton, Mass. For either the Alliance RT/1 or Sintech 1/S instrumentslisted above.

The following procedure illustrates the measurement when using the abovesample dimensions and either an Alliance RT/1 or Sintech 1/S. Theinstrument is interfaced with a computer. TestWorks 4® software controlsthe testing parameters, performs data acquisition and calculation, andprovides graphs and data reports.

The grips used for the test are wider than the sample. 2 inch (5.08 cm)wide grips may be used. The grips are air actuated grips designed toconcentrate the entire gripping force along a single line perpendicularto the direction of testing stress having one flat surface and anopposing face from which protrudes a half round (radius=6 mm) (Partnumber: 56-163-827 from MTS Systems Corp.) to minimize slippage of thesample.

The load cell is selected so that the forces measured will be between10% and 90% of the capacity of the load cell or the load range used. A25 Newton load cell may be used. The fixtures and grips are installed.The instrument is calibrated according to the manufacturer'sinstructions. The distance between the lines of gripping force (gaugelength) is 1 inch (25.4 mm), which is measured with a steel ruler heldbeside the grips, unless specified otherwise. The load reading on theinstrument is zeroed to account for the mass of the fixture and grips.The mass, thickness, and basis weight of the specimen are measuredbefore testing. The specimen is mounted into the grips in a manner suchthat there is no slack and the load measured is between 0.00 Newton and0.02 Newton, unless specified otherwise. The instrument is located in atemperature-controlled room for measurements performed at 22° C.

The hysteresis test method for film samples involves the following steps(all strains are engineering strains):

(1) Strain the sample to 500% strain at a constant crosshead speed of 10inches per minute (25.4 cm per minute) with no hold.(2) Reduce strain to 0% strain (i.e., return grips to original gaugelength of 1 inch) at a constant crosshead speed of 10 inches per minute(25.4 cm per minute) with no hold.(3) Hold sample for 1 minute at 0% strain(4) Pull the sample to 0.05 N force at a constant crosshead speed of0.51 inches per minute (13 mm per minute) and return to zero strain atthe same crosshead speed to measure the set in the material. The set orthe growth in the sample changes the gauge length. The method adds theextension up to the 0.05 N force to original 25.4 mm gauge length tocalculate New Gauge length.(5) Strain the sample to 200% strain based on new gauge length at aconstant crosshead speed of 10 inches per minute (25.4 cm per minute).(6) Hold at 200% strain for 30 seconds.(7) Go to 0% strain at a constant crosshead speed 10 inches per minute(25.4 cm per minute).

The method reports New Gauge length for each sample, which is the newlength of the sample after straining to 500% and one minute ofconsequent hold time at 0% strain. The New Gauge length is used tocalculate % set in the material as follow.

% Set=100*(New Gauge length−original gauge length)/original gauge length

Examples T-Peel Examples Example 1

Unactivated film KC 6282.810 available from Mondi GmbH, Gronau in 40 μmwas used as adherend. The film is made of elastic polyolefin resin usinga blown film extrusion process. It is a three layer film with elasticpolyolefin film in core, while the skin on each side is made of plasticpolyolefin. This film was bonded to PET film, using double sided tape.The T-peel sample was created using H2861 glue, and PET as described inthe method above.

Example 2

The film used in Example 1 was pre-activated using the incrementalstretching process as described in U.S. Pat. Nos. 5,143,679, 5,156,793and 5,167,897 patents issued to Weber et. al. It was pre-activated incross-direction using 0.150″ pitch roll at 6 mm Depth of Engagement.This created wrinkles in the film skins, as described and illustratedherein. The pre-activated film was used as adherend to create a T-Peelsample as described in the method above. The sample is mounted in a waythat it is peeled in machine direction (i.e., a direction parallel tothe activation lines).

Both samples (i.e., Example 1 and 2) were T-Peeled as per the methoddescribed above. When peeled, the adhesive, which was applied onadherend, peeled off completely from it and transferred to adherent PET.This was true for both samples. This indicated that T-Peel force wasindicative of adhesive failure between adhesive and adherend, and notbetween adhesive and adherent PET. FIG. 18 shows the T-Peel data curvesfor samples of Example 2. The difference in the bonding force wasevident in the T-Peel force data between two samples shown in Table 1below.

TABLE 1 T-Peel force data for various samples of examples 1 and 2.Standard Average Deviation 1 2 3 4 5 (N/cm) (N/cm) Example 1 0.7 0.650.66 0.67 0.03 Example 2 0.78 0.81 0.75 0.73 0.75 0.76 0.03

The pre-activated film of Example 2 showed higher bonding force comparedto the un-activated film of Example 1. Even though both samples testedare 1″ wide, the wrinkles in the pre-activated sample provides a largerbonding surface compared to the un-activated film. The corrugatedsurface on the film (wrinkles in the skin) has hills and furrows. Asadhesive is pushed into the furrows during bonding step, it increasescontact points and hence bonding area. The more bonding surface areatranslates into higher peel force. The stretch laminating process usesnipping after adhesive application to create a stronger bond. Havingfurrows and hills on the film surface therefore enhances the bondproperties.

T-Peel is often indicator of product robustness. The product consideredhere requires peel force higher than 0.5 N/cm between elastic film andsubstrate. Good bonding between the film and substrate preventsdelamination of the substrate or the film during product use. Example 2shows almost ˜14% increase in T-peel force. This increase in T-peelforce allows one to utilize less adhesive with a wrinkled film (wrinklesobtained through preactivation) to achieve identical performancecompared to the amount of adhesive that one would use on flat film as inExample 1. In the embodiments of the pre-activated stretch laminatescontemplated herein, the peel force, as measured by the T-Peel Methoddescribed above, are about 0.5 N/cm or more, more preferably about0.6n/cm or more.

Hysteresis (% Set) Examples Example 3

Styrenic block copolymer resin 21J (412-10225) available from Kuraray,was extruded to make film using Berstorff extruder ZE25. A 25.4 cm widecoat hanger cast film die is used to shape the compounded elastomermixture into a thin film, and a film take-off unit is positioned toreceive the extrudate which is collected on double sided silicone coatedrelease paper and wound onto a cardboard roll. For generating dataherein, a monolayer film is extruded at around 450 deg. F. at ˜35 gsm atvery low speed (˜10 ft/min). The film is collected from the 254 mm castfilm die, and the middle 127 mm is used for sample preparation.

Example 4

Polyolefin based elastomer Vistamaxx 6102 available from Exxon Mobil wasextruded to make a film using Berstorff extruder ZE25. The film wasextruded using the same set-up as in Example 3. A monolayer film wasextruded at around 450° F. at ˜35 gsm at very low speed (˜10 ft/min).

For the hysteresis analysis, both samples were cut from the middle ofthe film to eliminate any edge effect on the performance. Five samplesfor each example with dimension of 3″ in Cross direction and 1″ inMachine direction (extrusion direction) were cut. Mono-layer elasticfilms are harder to handle, and often powdered (corn starch or talc)before handling. These samples were then analyzed as per the hysteresismethod described above. Although the method measured various performanceparameters, Table 2 below lists the % set value for the materials

TABLE 2 % Set measured with Hysteresis method for samples of Ex. 3 andEx. 4. Standard Average Deviation 1 2 3 4 5 % Set % Set Example 3 21%21% 21% 22% 20% 21% 1% Example 4 56% 53% 55% 58% 55% 55% 2%

A new class of polyolefin materials made out of polypropylene showelastic behavior. However, they show very high set relative totraditional elastomers made of Styrenic block copolymers. Stretchlaminates made out of elastic film and non-elastic nonwovens oftenrequire mechanical activation to release elasticity. Mechanicalactivation is most commonly carried out in cross-direction. Duringactivation, if the elastic film shows high set, the post-activationprocess becomes unstable. To handle the elongated web process oftenrequires costly equipment and a large space. More importantly, the webelongation in cross-direction reduces the reliability and speed of theprocess. Styrenic block copolymer based films are commonly used in thering-rolling process and stretch laminate making process. As shown inTable 2 for Example 3, Styrenic Block copolymer films used in suchprocess show 20% to 25% set, at most 30% set when strained to 500% asdescribed in the hysteresis method. On contrary, the new generationelastic polypropylene films of Example 4 show about 55% set in thematerial. The film or laminate web with such high set will creates webhandling challenges and requires new capital. However, this can beaddressed by pre-activating film. Once the set in the material isinduced via pre-straining, material sees less set in the consequentactivation steps. In addition, elastic polyolefin materials show betterhysteresis properties after pre-activation, compared to one beforepre-activation. In the embodiments of the pre-activated stretchlaminates contemplated herein, the % set, as measured by the HysteresisMethod described above, are about 30% or more, and preferably about 35%or more.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm”.

All documents cited in the Detailed Description are, in relevant part,incorporated herein by reference; the citation of any document is not tobe construed as an admission that it is prior art with respect to thepresent invention. To the extent that any meaning or definition of aterm in this disclosure conflicts with any meaning or definition of theterm in a document incorporated by reference, the meaning or definitionassigned to the term in this disclosure shall govern for thisdisclosure.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. An absorbent article comprising: i) a chassiscomprising a topsheet, a backsheet, and an absorbent core disposedbetween the topsheet and the backsheet; and ii) at least one elasticallyelongatable panel joined to the chassis, wherein the elasticallyelongatable panel comprises an ultrasonically bonded stretch laminatecomprising: a. a first nonwoven and a second nonwoven, b. an elastomericfilm sandwiched between the first and second nonwovens, wherein theelastomeric film having two surfaces and a skin on at least one of thesurfaces; and c. a first zone and second zone, wherein: i. in the secondzone, the laminate is elastically extensible in a stretch direction; ii.in the first zone, the laminate is unactivated and the elastomeric filmcomprises activation stripes.
 2. The absorbent article of claim 1wherein the skin comprises polyolefin.
 3. The absorbent article of claim2 wherein the skin comprise polyethylene.
 4. The absorbent article ofclaim 1 wherein the film comprises elastically extensible materialsselected from the group comprising: styrene-isoprene-styrene blockcopolymers, styrene-butadiene-styrene block copolymers,styrene-ethylene-butylene-styrene block copolymers, polyurethanes,ethylene copolymers, polyether block amides, and combinations thereof.5. The absorbent article of claim 1 further comprising a fastener joinedto elastically elongatable panel, wherein the elastomeric film is inpartial overlapping relationship with the fastener.
 6. The absorbentarticle of claim 5 wherein the elastically elongatable panel is joinedto the fastener in at least in a portion of the first zone.
 7. Theabsorbent article of claim 1 wherein the elastomeric film is betweenabout 20 μm and about 60 μm thick.
 8. The absorbent article of claim 7wherein the elastomeric film is about 50 μm thick.
 9. The absorbentarticle of claim 1 wherein the first nonwoven and/or the second nonwovencomprises a basis weight of about 30 gsm or less.
 10. The absorbentarticle of claim 1 wherein the first nonwoven and/or the second nonwovencomprises a spunbond layer and/or a meltblown layer.
 11. The absorbentarticle of claim 1 wherein the first nonwoven is directly bonded to thesecond nonwoven.
 12. An absorbent article comprising: i) a chassiscomprising a topsheet, a backsheet, and an absorbent core disposedbetween the topsheet and the backsheet; and ii) at least one elasticallyelongatable panel joined to the chassis, wherein the elasticallyelongatable panel comprises an ultrasonically bonded stretch laminatecomprising: a. a first nonwoven and a second nonwoven, i. an elastomericfilm sandwiched between the first and second nonwovens, wherein theelastomeric film having two surfaces and a skin on at least one of thesurfaces; and b. a first zone and second zone, wherein: i. in the secondzone, the laminate is elastically extensible in the stretch direction;ii. in the first zone, the laminate is unactivated; and wherein at leasta portion of the skin of the elastomeric film is located in the firstzone and wherein said portion of the skin has a plurality of wrinklesand the wrinkles have furrows.
 13. The absorbent article of claim 12wherein the skin comprises polyolefin.
 14. The absorbent article ofclaim 12 wherein the film comprises elastically extensible materialsselected from the group comprising: styrene-isoprene-styrene blockcopolymers, styrene-butadiene-styrene block copolymers,styrene-ethylene-butylene-styrene block copolymers, polyurethanes,ethylene copolymers, polyether block amides, and combinations thereof.15. The absorbent article of claim 12 further comprising a fastenerjoined to elastically elongatable panel wherein the elastomeric film isin at least partial overlapping relationship with the fastener.
 16. Theabsorbent article of claim 15 wherein the elastically elongatable panelis joined to the fastener in at least in a portion of the first zone.17. The absorbent article of claim 12 wherein the elastomeric film isbetween about 20 μm and about 60 μm thick.
 18. The absorbent article ofclaim 12 wherein the first nonwoven and/or the second nonwoven comprisesa basis weight of about 30 gsm or less.
 19. The absorbent article ofclaim 12 wherein the first nonwoven and/or the second nonwoven comprisesa spunbond layer and/or a meltblown layer.
 20. An absorbent articlecomprising: i) a chassis comprising a topsheet, a backsheet, and anabsorbent core disposed between the topsheet and the backsheet; and ii)at least one elastically elongatable panel joined to the chassis,wherein the elastically elongatable panel comprises an ultrasonicallybonded stretch laminate comprising: c. a first nonwoven and a secondnonwoven, d. an elastomeric film sandwiched between the first and secondnonwovens, wherein the elastomeric film having two surfaces and a skinon at least one of the surfaces; and e. a first zone and second zone,wherein: i. in the second zone, the laminate is elastically extensiblein the stretch direction; and ii. in the first zone, the laminate isinelastic and the elastomeric film comprises activation stripes; andwherein first and second nonwovens are directly bonded.
 21. Theabsorbent article of claim 20 wherein the skin comprises polyolefin. 22.The absorbent article of claim 20 wherein the film comprises elasticallyextensible materials selected from the group comprising:styrene-isoprene-styrene block copolymers, styrene-butadiene-styreneblock copolymers, styrene-ethylene-butylene-styrene block copolymers,polyurethanes, ethylene copolymers, polyether block amides, andcombinations thereof.
 23. The absorbent article of claim 20 furthercomprising a fastener attached to elastically elongatable panel at leastin a portion of the first zone.
 24. The absorbent article of claim 20wherein the elastomeric film is between about 20 μm and about 60 μmthick.
 25. The absorbent article of claim 20 wherein the first nonwovenand/or the second nonwoven comprises a basis weight of about 30 gsm orless.
 26. The absorbent article of claim 20 wherein the first nonwovenand/or the second nonwoven comprises a spunbond layer and/or meltblownlayer.